US6516984B1

US6516984B1 - Vehicle article carrier for supporting articles adjacent a liftgate of a vehicle

Info

Publication number: US6516984B1
Application number: US09/698,761
Authority: US
Inventors: Gerard J. Kmita; Jeffrey M. Aftanas; Milton J. Antonick; Brett J. Borella
Original assignee: JAC Products Inc
Current assignee: JAC Products Inc
Priority date: 2000-03-17
Filing date: 2000-10-27
Publication date: 2003-02-11
Anticipated expiration: 2020-03-17
Also published as: US6338427B1; JP2001260760A; DE60107739D1; DE60107739T2; EP1134121B1; EP1134121A2; EP1134121A3

Abstract

An article carrier adapted to hold cargo and other articles adjacent a liftgate of a vehicle such as a sport utility vehicle, a station wagon or minivan. The article carrier includes a pair of supports which are fixedly secured to the roof of the vehicle. A cargo supporting structure having a pair of upper coupling links is pivotally and releasably coupled to the supports. The cargo supporting structure includes a pair of main support members which each include a pair of pivot assemblies at upper and lower ends thereof. The pivot assemblies at the lower end of the cargo supporting structure are detachably secured to a pair of anchor assemblies attached to the liftgate of the vehicle. The three pivot points along each side of the cargo supporting structure enable it to be pivoted with the liftgate when the liftgate is lifted and closed such that the article carrier does not interfere with operation of the liftgate. The entire article carrier can be quickly and easily detached from the vehicle for storage when it is not needed.

Description

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation-in-part of U.S. application Ser. No. 09/528,765, filed Mar. 17, 2000, which issued on Jan. 15, 2002, as U.S. Pat. No. 6,338,427.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to vehicle article carrier systems, and more particularly to a multi-position vehicle article carrier system having a cargo supporting structure capable of being secured over a liftgate of a vehicle and moved into a second position over a roof portion of the vehicle once cargo is loaded onto the cargo supporting structure.

2. Discussion

Vehicle article carriers are used in a wide variety of vehicles to support cargo and various other articles above an outer body surface, such as a roof portion, of a vehicle. Typically, such systems include a pair of side rails or slats which are fixedly secured to the roof portion of the vehicle. Usually a pair of cross bars are secured to the side rails or slats to extend transversely therebetween. The cargo is then positioned on the cross bars and secured down via suitable securing straps or bungee cords so that the cargo is held securely on the article carrier while the vehicle is in use.

One drawback with any conventional vehicle article carrier system is the occasional difficulty of lifting cargo and other articles to be transported up onto the roof portion of the vehicle. This is particularly so if the vehicle is a sport utility vehicle or a mini van, in which case the roof thereof is often at a height which is higher than many individuals can reach easily when attempting to lift cargo onto the article carrier. Removing cargo from the vehicle article carrier can often be just as difficult depending, of course, on the specific cargo, its dimensions and its weight.

Some attempts have been made to overcome this problem by providing a vehicle article carrier which has some form of movable load supporting structure which can be disposed in a temporary position in which cargo can be more easily loaded thereunto. Such systems, for example, are illustrated in U.S. Pat. Nos. 5,649,655; 5,505,579 and 5,417,358.

The systems illustrated in the above-mentioned patents typically suffer from one or more drawbacks. Often, such systems are complex to manufacture, and therefore costly. With some such devices, they cannot be left in a “lowered” position, but rather must be maintained in a retracted position on top of the vehicle roof. Some also do not allow for convenient opening of the liftgate of a vehicle when the cargo supporting portion is in its lowered position.

Yet another drawback with such pre-existing article carrier systems as described above is the inability to remove the cargo supporting portion of the system when it is not needed. It would also be advantageous to be able to collapse the removed cargo supporting portion into a compact arrangement that could be stored in a duffle bag or other like implement and then stored in a garage, or even in the vehicle from which it was removed.

It is therefore a principal object of the present invention to provide a vehicle article carrier having a cargo supporting structure which can be secured over the liftgate of a vehicle to thus allow cargo to be secured thereto without a user having to stand on a ladder or other implement, as with conventional roof mounted article carrier systems.

It is another object of the present invention to provide a vehicle article carrier in which a cargo supporting structure is used to support cargo adjacent a liftgate of a vehicle, and which also permits the liftgate to be lifted and lowered without interference from the article carrier, and further which does not add an appreciable amount of weight to the liftgate.

It is yet another object of the present invention to provide a vehicle article carrier having a cargo supporting structure which is mounted over a liftgate of a vehicle, and where the cargo supporting structure can be quickly and easily detached from the vehicle when the cargo supporting structure is not needed, and which can further be collapsed into a compact arrangement for storage.

SUMMARY OF THE INVENTION

The above and other objects are provided by a multi-position, articulating, vehicle article carrier apparatus and method. In one embodiment the apparatus includes a pair of side rails adapted to be fixedly disposed on a roof portion of a vehicle such as a station wagon, sport utility vehicle (SUV) or minivan. The side rails each include channels for receiving articulating assemblies which are slidably disposed on the side rails. Pivotally secured to the articulating assemblies is a cargo supporting structure. The cargo supporting structure includes at least one, but preferably a pair, of cross bars for supporting cargo thereon. The cargo supporting structure may be secured at its free end to a portion of the vehicle such as the bumper or even portions of the vehicle body extending alongside the liftgate.

The cargo supporting structure includes an actuator bar assembly disposed adjacent to its free end which may be grasped with one hand by an individual and turned. This simultaneously unlocks at least one, but preferably a pair, of locking mechanisms which otherwise secure the free end of the cargo supporting structure to the bumper or vehicle body. Once unlocked, the cargo supporting structure can be lifted upwardly to an intermediate position extending generally parallel to the roof portion of the vehicle. Once in this position, a camming mechanism associated with the articulating assembly automatically unlocks the articulating assembly such that the entire articulating assembly and cargo supporting structure can be moved slidably along the side rails onto the roof portion of the vehicle. Once disposed over the roof portion, the free end of the cargo supporting structure can be secured to a pair of locking assemblies associated with each of the side rails.

It is an advantage of the vehicle article carrier of the present invention that the end of the cargo supporting structure pivotally secured to the articulating assemblies is locked against movement until the entire cargo supporting structure is lifted into the intermediate position, whereupon automatic unlocking of the articulating assemblies occurs. Thus, the cargo supporting structure is held fixedly in a very stable position whether it is disposed over the liftgate of the vehicle (i.e., in a “lowered” position) or on top of the vehicle. Accordingly, cargo can be loaded and supported on the cargo supporting structure not only while the structure is disposed on top of the vehicle, but while the cargo supporting structure is disposed in its lowered position over the liftgate. Being able to load and unload cargo while the cargo supporting structure is in its lowered position adds significantly to the ease in loading and unloading cargo from the article carrier.

It is also an important advantage of the present invention that the article carrier thereof does not interfere with opening and closing of the liftgate once the cargo supporting structure is unlocked from the bumper or body portion of the vehicle. Thus, access can be gained to the interior of the vehicle through the liftgate quickly and easily, and even while cargo is secured to the cargo supporting structure. All that is required is for the user to manually rotate the actuator bar assembly to unlock the free end of a cargo supporting structure from the bumper or body of the vehicle, lift the cargo supporting structure into the intermediate position and then slide it forwardly over the roof of the vehicle.

The multi-position, articulating, vehicle article carrier of the present invention thus provides an easy and convenient means of loading cargo onto a portion of the article carrier and transporting the cargo either over the liftgate of the vehicle or on top of the vehicle. The cargo supporting structure of the vehicle article carrier is further lightweight, easily articulated by a single person, and provides significant added ease in loading, positioning and unloading cargo onto and off of the vehicle article carrier.

In an alternative preferred embodiment of the present invention an articulating article carrier is disclosed which is adapted to support articles solely adjacent the lift gate of the vehicle. This embodiment includes a cargo supporting structure which is pivotally attached to a pair of supports. The supports are fixedly mounted on a roof portion of a vehicle such as a sport utility vehicle, station wagon or minivan. The cargo supporting structure includes a pair of upper coupling links which are pivotally, and also removably, attached to the supports at first ends thereof. A second end of each upper coupling link is attached to one of a first pair of pivot assemblies. The upper pivot assemblies are disposed adjacent an upper edge of the liftgate but rearwardly of the pair of supports.

The cargo supporting structure also includes a pair of main support members which are also secured to the pivot assemblies. The main support members extend down over and adjacent to the liftgate. Preferably, one or more cross bars are removably attached perpendicularly between the two main support members. A lower end of each of the main support members is also attached to a second pair of pivot assemblies, which are in turn each attached to an associated anchor assembly. The anchor assemblies are fixedly secured to the liftgate to hold the cargo supporting structure stationary over the liftgate. The first and second pivot assemblies, as well as the pivotal attachment to the supports, allows the article carrier to be articulated as the liftgate is opened so that no detachment of the article carrier from the liftgate or from the support members is required before opening the liftgate.

A principal advantage of the just described embodiment is that the article carrier can be quickly and easily removed from the vehicle without complicated disassembly procedures and without the need for special tools. Once removed, the article carrier can be folded into a compact arrangement for storage. The folded article carrier is compact enough that it can even be stored within the cargo area of the vehicle if desired. Re-installation of the article carrier can be accomplished in minutes, again without special tools or procedures.

BRIEF DESCRIPTION OF THE DRAWINGS

The various advantages of the present invention will become apparent to one skilled in the art by reading the following specification and subjoined claims and by referencing the following drawings in which:

FIG. 1 is a perspective view of a rear portion of a vehicle illustrating a preferred embodiment of a multi-position, articulating, article carrier apparatus in accordance with the present invention secured to the outer body surface of the vehicle, with the apparatus in a first or lowered position;

FIG. 2 is a view of the apparatus and vehicle shown in FIG. 1 with the apparatus disposed in an intermediate position about to be urged over a roof portion of the vehicle;

FIG. 3 is a plan view of the apparatus of FIG. 1 showing the apparatus in a second position in which a cargo supporting structure thereof is disposed over the roof portion of the vehicle;

FIG. 4 is a perspective view of one of the latching assemblies secured to a support beam on the rear bumper of the vehicle of FIG. 1;

FIG. 5 is a cross sectional side view of the free end of the cargo supporting structure secured to the latching assembly, taken in accordance with section line 5—5 in FIG. 1;

FIG. 6 is a cross sectional side view of the latching assembly of FIG. 5 with the lower locking assembly of the cargo supporting structure unlatched therefrom and ready to be lifted away from the bumper;

FIG. 6a is a fragmentary side, cross-sectional view of the latching lever of FIG. 5 engaging the latching assembly as the latching lever is urged into the latching assembly;

FIG. 7 is a perspective fragmentary view of a portion of the torque rod assembly of the cargo supporting structure illustrating one of the lower locking assemblies at one end of the torque rod assembly;

FIG. 8 is a cross sectional view of a portion of the torque rod assembly shown in FIG. 7 taken in accordance with section line 8—8 in FIG. 7;

FIG. 9 is a cross sectional view of the torque rod assembly taken in accordance with section line 9—9 in FIG. 8;

FIG. 10 is a plan view of the rear portion of one of the side rails also showing the articulating assembly and a small portion of the cargo supporting structure;

FIG. 11 is a perspective view of the articulating assembly and the rearmost end portion of one of the side rails;

FIG. 11a is a plan view of an end portion of the articulating assembly illustrating the pair of rollers that are used for enabling rolling movement of the articulating assembly along its associated side rail;

FIG. 12 is a side view of the articulating assembly when the cargo supporting structure is disposed in the lowered position shown in FIG. 1;

FIG. 13 is a side view of the articulating assembly when the cargo supporting structure is moved into the intermediate position shown in FIG. 2;

FIG. 14 is a cross sectional side view of the articulating assembly in accordance with section line 14—14 in FIG. 10, when the cargo supporting structure is in the lowered position of FIG. 1;

FIG. 15 is a cross sectional side view of the articulating assembly of FIG. 14 with the cargo supporting structure raised into the intermediate position of FIG. 2;

FIG. 16 is a partial cross sectional view of the side rail taken in accordance with section line 16—16 in FIG. 11;

FIG. 17 is a cross sectional side view of the upper locking assembly of one of the rear supports, taken in accordance with section line 17—17 in FIG. 3;

FIG. 18 is a perspective view of an alternative preferred embodiment of the present invention;

FIG. 19 is a perspective view of the article carrier of FIG. 18 with the cargo supporting structure thereof in a lowered position;

FIG. 20 is a perspective view of another alternative preferred embodiment of the present invention; and

FIG. 21 is a perspective view of the article carrier of FIG. 20 with the cargo supporting structure thereof in the lowered position;

FIG. 22 is a perspective view of another alternative preferred embodiment of the article carrier of the present invention;

FIG. 23 is a side view of the article carrier shown in FIG. 22 but with the liftgate of the vehicle in the open position;

FIG. 23A is a cross sectional end view taken in accordance with section line 23A—23A in FIG. 22;

FIG. 24 is a perspective view of a portion of one of the main support members showing one of the cross bars secured thereto in a storage arrangement when the article carrier is not being used and is removed from the vehicle;

FIG. 25 is an exploded perspective view of the components comprising the upper pivot assembly;

FIG. 26 is a perspective view of an alternative preferred embodiment of the pivot assembly;

FIG. 27 is an end view of one of the supports showing a portion of one of the upper coupling links pivotally coupled thereto;

FIG. 28 is an exploded perspective view of one of the anchor assemblies fixedly attached to the rear liftgate; and

FIG. 29 is a side cross sectional view of a portion of the lower pivot assembly engaged with the anchor assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1 there is shown a multi-position, articulating, vehicle article carrier apparatus 10 in accordance with a preferred embodiment of the present invention. The apparatus 10 is shown secured to a roof portion 12 a of a motor vehicle 12. While the motor vehicle 12 is illustrated as a sport utility vehicle (SUV), it will be appreciated that the apparatus 10 could also be used with minivans, station wagons, and a wide variety of other vehicles, and is therefore not limited to use with any particular type of vehicle.

The apparatus 10 includes a pair of side rails 14 which are adapted to be fixedly secured to the roof portion 12 a of the vehicle 12. Each side rail 14 includes a rear support 16 and a front support 17 which support a main portion 14 a of the side rail 14 above the roof portion 12 a. Each of the main portions 14 a of each side rail 14 comprise C-shaped channels.

A pair of articulating mechanisms 18 are engaged with the side rails 14 so as to be movable along each of the side rails 14. The articulating mechanisms 18 are pivotably secured to a cargo supporting structure 20. The cargo supporting structure 20 includes a frame comprised of side members 22, a transversely extending top frame member 24 and an actuator bar assembly 26. At least one cross bar 25, and more preferably a pair of cross bars 25, are disposed on the cargo supporting structure 20 to extend between the side members 22. The cross bars 25 may be fixedly secured to the side members 22 or clamping assemblies or other means may be employed to permit adjustable positioning of the cross bars 25 along the side members 22. Securing straps such as bungee cords may be used to secure cargo on the cross bars 25.

A lower or free end 28 of the cargo supporting structure 20 includes a pair of lower locking assemblies 30. These lower locking assemblies 30 are each adapted to latch with a corresponding pair of latching assemblies 32 disposed within a rear bumper 34 of the vehicle 12.

Referring to FIGS. 1-3, the apparatus 10 can be secured in a first or lowered position disposed over a liftgate 12 b, as shown in FIG. 1. In this position cargo can be carried on the cargo supporting structure 20 through the use of suitable fastening straps or bungee cords or like components which secure the cargo to the cross bars 25. In FIG. 2, the cargo supporting structure 20 is shown after same has been raised into an intermediate position. This is accomplished by a user actuating the actuator bar assembly 26 to release the lower locking assemblies 30 from the latching assemblies 32, and then lifting upwardly on the free end 28 of the cargo supporting structure 20. FIG. 3 shows the cargo supporting structure 20 after same has been slid forwardly over the roof portion 12 a of the vehicle 12. In this position the lower locking assemblies 30 can be locked to a corresponding pair of upper locking assemblies 36 associated with the two rear supports 16.

Referring now to FIGS. 4 and 5, one of the latching assemblies 32 is shown. The latching assembly 32 includes a main body portion 38 and a latching door 40 pivotably secured by a pivot pin 42 to the main body portion 38. The latching door 40 includes a lower end 44 which is biased by a spring 46 secured to a transversely extending pin 50. Thus, the latching door 40 is constantly biased into the closed position shown in FIG. 4. A base portion 52 allows the main body portion 38 to be secured to a structural frame member 54 disposed within the bumper 34. The base portion 52 is preferably secured to the structural member 54 by a plurality of threaded fastening members 58 extending through apertures 52 a in the base portion 52. An upper wall 56 of the main body portion 38 sits generally flush with an upper outer surface of the bumper 34 to present an aesthetically pleasing appearance whether or not the cargo supporting structure 20 is in the lowered position shown in FIG. 1.

Referring now to FIGS. 7-9, the actuator bar assembly 26 will be described. Referring specifically to FIGS. 7 and 8, the actuator bar assembly 26 includes a centrally disposed, manually graspable and rotatable member 60. Rotatable member 60 is disposed over a first sleeve portion 62 and supported by a pair of support rings 64 which are also disposed over the first sleeve 62. The first sleeve 62 extends completely to each opposite end 66 of the actuator bar assembly 26 and is secured by at least one fastening member 68 within an end cap portion 70. A free wheeling sleeve 72 is disposed on each side of the rotatable sleeve 60 inbetween one of the supports 64 and one of the end cap portions 70. The free wheeling sleeve 72 rotates freely while being grasped when the free end 28 of the cargo supporting structure 20 is lifted from the lowered position of FIG. 1 into the intermediate position of FIG. 2.

With further reference to FIGS. 8 and 9, the rotatable sleeve 60 is secured to a torque rod 76 via a threaded member 74 which extends into a threaded bore 76 a in the torque rod 76. A spacer sleeve 78 (also shown in FIG. 7) also receives the threaded member 74 therethrough. The first sleeve 62 includes a slot 80 extending over an arc of slightly greater than 90°. Slot 80 permits the rotatable sleeve 60 and the threaded member 74 to be rotated without interference from the first sleeve 62. Thus, when the rotatable sleeve 60 is rotated, this rotational movement is transmitted to the torque rod 76.

With specific reference to FIG. 7, each opposite end of the torque rod 76 includes a half moon shaped protrusion 82 which forms a camming surface 82 a.

Camming surface

82 a is used to control locking and unlocking of its associated lower locking assembly 30, which will be described momentarily. It will thus be appreciated that the actuator bar assembly 26 allows an unlocking action to be effected which releases the two lower locking assemblies 30 simultaneously from their respective latching assemblies 32 simply through a short twisting motion of the rotatable sleeve 60. Thus, unlocking of the actuator rod assembly 26 from the lower locking assemblies 32 can be effected with only one hand of a user and with a simple, short and convenient rotational movement of the rotatable sleeve 60.

Referring now to FIGS. 5-7, the construction and operation of one of the pair of lower locking assemblies 30 will be described. Each lower locking assembly 30 includes a latching lever 84 having an upper end 86 and a lower end 88. The latching lever 84 is pivotally mounted via a pivot pin 90 which extends through an aperture 92 in the lever 84 and also through a main body portion 94 which partially encloses the latching lever 84.

With specific reference to FIG. 5, a spring 96 is disposed against an inside surface 22 a of a tubular portion 22 b of the side member 22, and extends through an opening 100 in the main body portion 94 into a notch 98 formed in the latching lever 84. The spring 96 biases the lower end 88 of the latching lever 84 upwardly into a closed or latched position, which is shown in FIG. 5.

With reference to FIGS. 5, 6 and 7, when the rotatable sleeve 60 is grasped with one hand and rotated, the camming surface 82 a of the protrusion 82 rotates to urge the upper end 86 of the latching lever 84 pivotally about the pivot pin 90. As the latching lever 84 rotates, the lower end 88 thereof is drawn away from the upper wall 56 of the latching assembly 32 (FIG. 6). This allows a lip portion 102 of the latching lever 84 to be drawn out of a notch 104 formed in an undersurface of the upper wall 56. While the rotatable sleeve 60 is held in the rotated position, the user lifts the free end 28 of the cargo supporting structure 20 upwardly and away from the latching assembly 32.

When the free end 28 of the cargo supporting structure 20 is lowered into latching engagement with the latching assemblies 32, no rotational movement of the rotatable sleeve 60 is required for proper latching of the lower locking assemblies 30 to occur. As the lower end 88 of each latching lever 88 contacts its respective latching door 40, an edge portion 94 a of the main body portion 94 engages the latching door 40 and urges this component downwardly into the position shown in FIGS. 5 and 6. Referring to FIG. 6a, further lowering movement of the cargo supporting structure 22 causes the lip portion 102 to engage an interior edge 106 of the upper wall 56. Further lowering movement causes the lip 102 to ride over the interior edge 106 before snapping into engagement in the notch 104 (FIG. 5).

Referring now to FIGS. 10-15, the construction and operation of the articulating mechanisms 18 will be described. With initial reference to FIGS. 10, 11 and 11 a, each articulating mechanism 18 includes a pair of rollers 110 which are pivotally secured via axles 112 within cut-outs 119 a of a support bar 119. The support bar 119 is sized so as to be able to fit within a C-shaped channel 14 b of the side rail 14 and through a C-shaped channel 116 a (FIG. 11) in the rear support 16. During assembly, the articulating mechanism 18 is inserted through the C-shaped channel 116 a in the rear support 16 and a stop member 114 is secured to the support bar 119 via a threaded member 116. The stop member 114 prevents the articulating mechanism 18 from being withdrawn beyond a predetermined point from its respective side rail 14.

With further reference to FIGS. 11 and 14, the support bar 119 includes a slot 120 formed therein within which is disposed a locking bar 122. The locking bar 122 is pivotally mounted at a central aperture 123 by a pivot pin 126 extending through the support bar 18. An elongated, linear slot 124 is also formed in the support bar 18. This slot 124 further includes a relief portion 124 a to allow clearance for a cam lobe 128. The slot 124 may vary in length, but in one preferred form is between about six-nine inches.

With reference to FIGS. 14 and 15, a threaded member 132 extends through an opening 134 in a first end 136 of the locking bar 122. The threaded member 132 captures a biasing member 138 within the opening 134. Biasing member 138 serves to provide a constant biasing force which tends to bias the first end 136 of the locking bar 122 upwardly into the position shown in FIG. 15.

With reference to FIGS. 10 and 14, the top frame member 24 includes an axle portion 24 a at each end thereof. The axle portions 24 a each have attached thereto at their outermost ends one of the cam lobes 128. Thus, the axle portions 24 a pivotally support the cargo supporting structure 20 from the articulating mechanisms 18. Importantly, the axle portions 24 a also are able to slide within the elongated slots 124 when the cargo supporting structure 20 is moved from the intermediate position of FIG. 2 to the position shown in FIG. 3.

Referring now to FIGS. 12, 13, 14 and 15, when the cargo supporting structure 20 is in the lowered position shown in FIG. 1, the side members 22 are disposed in the position shown in FIG. 12. In this position the cam lobe 128 is engaged in the relief portion 124 a, as illustrated in FIG. 14. This allows the cam lobe 128 to lift a second end 140 of the lock bar 122 which causes the first end 136 to project outwardly of the support bar 119. The first end 136 abuts a notch 142 formed in the rear support 16 which prevents the articulating mechanism 18 from moving inadvertently towards and into the support member 16 when the cargo supporting structure 20 is in the lowered position of FIG. 1. Thus, when in the lowered position shown in FIG. 1, the cargo supporting structure 20 is fixedly disposed. Its upper end 20 a cannot be pulled outwardly away from the upper supports 16 because of abutting engagement of the stop members 114 with their respective supports 16. Abutting engagement of the first end 136 of each locking bar 122 with the notch 142 of each support 16 prevents the upper end 20 a from being pushed in toward the side rails 14. Accordingly, cargo supported on the cross bars 25 of the cargo supporting structure 20 can be supported just as securely with the structure 20 in the lowered position as when the structure 20 is disposed over the roof portion 12 a of the vehicle 12.

When the cargo supporting structure 20 is lifted into the intermediate position shown in FIG. 2, the cam lobe 128 rotates in accordance with rotational movement of the top frame member 24 (FIG. 1) into the position shown in FIG. 13. This rotation of the cam lobe 128 allows the spring 138 to bias the first end 136 of the locking bar 122 upwardly into the position shown in FIG. 15. In this position the locking bar 122 is now able to clear the notch 142. Accordingly, the entire articulating mechanism 18 may be urged forwardly (i.e., to the right in the drawings of FIGS. 12-15) through the C-shaped channels 16 a in each of the rear supports 16. This unlocking action is further accomplished automatically by simply raising the free end 28 of the cargo supporting structure 20 into the intermediate position shown in FIG. 2.

Once the individual has raised the cargo supporting structure 20 into the position shown in FIG. 2, the entire cargo supporting structure can be pushed forwardly until the structure 20 is positioned over the roof portion 12 a of the vehicle 12. During the initial six-nine inches of forward travel, the axle portions 24 a slide forwardly within the elongated slots 124 before contacting forward ends 124 b of the slots 124. This six-nine inches of “travel” provides the distance necessary to place the pivot axis defined by the axle portions 24 a sufficiently behind the vehicle 12 so that the vehicle 12 does not interfere with lowering pivotal movement of the cargo supporting structure 20.

Another important advantage of the articulating mechanisms 18 is that they effectively allow the top frame member 24 to be positioned rearwardly of the pivot axis of the liftgate 12 b of the vehicle 12 such that the cargo supporting structure 20 can be lifted with the liftgate 12 b without first having to place the structure 20 over the roof portion 12 a of the vehicle 12. Thus, access can easily be gained to the rear of the vehicle 12 once the cargo supporting structure 20 and liftgate 12 b are both in the raised position.

Referring now to FIGS. 11 and 17, the securing of one of the lower locking assemblies 30 to one of the upper locking assemblies 36 (also shown in FIG. 3) will be described. Each of the upper locking assemblies 36 comprises a housing 146 which is preferably integrally formed with an associated one of the rear supports 16. Within the housing 146 is upstanding structure 148 and a transversely extending latch member 150. When the cargo supporting structure 20 is to be secured over the roof portion 12 a of the vehicle 12, it is urged into position over the roof portion 12 a such that the lower locking assembly 30 is over, but slightly forwardly, of the upstanding structure 148. The locking assembly 30 can then be lowered into an interior area of the housing 146. As the lower locking assembly 30 is lowered into the interior area of the housing 146, the lip portion 102 of the latch lever 84 contacts an upper edge 150 a of the transversely extending latch member 150 and pivots slightly against the biasing force of the spring 96 so as to clear the edge 150 a. The lip portion 102 then latches under the latch structure 150. In the position shown in FIG. 17, the lower locking assembly 30 is secured against movement.

Unlocking of the lower locking assembly 30 is accomplished by a user grasping and rotating the rotatable sleeve 60, which causes the latching lever 84 to pivot counterclockwise in the drawing of FIG. 17. While holding the rotatable sleeve 60 in its rotated position against the biasing force of spring 96, the user may then push the entire cargo supporting structure 20 forwardly just slightly before lifting the free end 28 of the structure 20 and then pulling same away from the vehicle 12 into the position shown in FIG. 2. Accordingly, unlatching of the cargo support structure 20 from the position shown in FIG. 3 can be accomplished by the user merely grasping the rotatable sleeve 60 and, from a single position behind the vehicle 12, articulating the actuator bar assembly 26 to clear the upper locking assembly 36. Thus, there is no need for the user to separately unlock each of the lower locking assemblies 30. This significantly adds to the convenience and ease in using the apparatus 10.

From the foregoing description, it will be appreciated that the apparatus 10 of the present invention provides an articulatable article carrier assembly which enables cargo to be carried either in a generally horizontal position over the liftgate of a vehicle, or on top of the vehicle, depending upon the user's preference. The apparatus 10 of the present invention significantly eases the manner with which cargo may be loaded, since the cargo need not be positioned directly on top of the vehicle 12 but rather on the cross bars 25 while the cargo supporting structure 20 is disposed over the liftgate 12 b. In this regard, it will be appreciated that one or both of the cross bars 25 could include perpendicularly extending portions which serve to temporarily support cargo which is positioned on the cross bars 25 when the cargo supporting structure 20 is in the lowered position shown in FIG. 1. The apparatus 10 can further be locked and unlocked from the position shown in FIGS. 1-3 with a simple, single movement of the rotatable sleeve 26, which thus serves to significantly enhance the ease with which the cargo supporting structure 20 can be moved between its various positions.

Referring now to FIGS. 18 and 19, an alternative preferred embodiment 200 of the multi-position, articulating, vehicle article carrier apparatus is illustrated. The apparatus 200 includes a cargo supporting structure 202 comprising a pair of cross bars 204 and a pair of side members 206 (only one being visible). With the apparatus 200, however, a pair of rear supports 208 and a pair of front supports 210 are used to support the cargo supporting structure 202 above the outer body surface 12 a of the vehicle 12. Each rear support 208 includes a suitable latching structure which can be actuated through opening and closing of a pivoting lever 209 to engage a suitably shaped cavity 212 (FIG. 19) in an outer body surface portion 214 of the vehicle 12. The front supports 210 each include a latching structure therein which can be locked and unlocked via a liftable locking lever 216 (shown in phantom in the lifted position in FIG. 19).

When the apparatus 200 is in the position shown in FIG. 18, the cargo supporting structure 202 is disposed over the roof portion 12 a of the vehicle 12. The internal locking structure within the front supports 210 secures the front supports to conventional slats 218 which are fixedly secured to the roof portion 12 a of the vehicle 12, and which each include channels which captively hold portions of the front supports 210 to the slats 218. This construction for the slats and the interengagement of the front supports 210 with the slats 218 to permit sliding movement of the front supports 210 along the slats 218 is well known in the art. Patents of the assignee of the present application which disclose suitable constructions for the locking assembly of the front support 210, which could be utilized with little or no modifications, are U.S. Pat. Nos. 4,899,917; 4,972,983; 4,982,886; 5,385,285 and 5,579,970, which are all incorporated by reference herein. In FIG. 19, the cargo supporting structure 202 is shown disposed over the liftgate 12 b of the vehicle 12. The rear supports 208 can be locked at one of a plurality of positions defined by cavities 212.

Referring now to FIGS. 20 and 21, a multi-position, articulating, vehicle article carrier 300 in accordance with yet another alternative preferred embodiment of the present invention is shown. The apparatus 300 is similar to the apparatus 200 and includes a cargo supporting structure 302 comprised of a pair of cross bars 304 and a pair of side members 306 (only one being visible). The cargo supporting structure 302 is supported above the roof portion 12 a of the vehicle 12 by a pair of rear supports 308 and a pair of front supports 310 (with only one of each

support

308 and 310 being visible). The front supports 310 are disposed on conventional slats 312 such that the front supports 310 can be moved slidably along the slats. The slats 312 are fixedly secured to the roof portion 12 a of the vehicle 12. Each slat 312 further includes a latching assembly 314 to which one of the rear supports 308 may be releasably secured.

To move the cargo supporting structure 302 from the position shown in FIG. 20 into the position shown in FIG. 21, the user first unlatches the front supports 310 by pulling outwardly on lever portions 316 of each of the front supports 310. This unlocks each front support 310 from its associated slat 312 and allows the front support 310 to be slid along its associated slat 312. Each rear support 308 is also unlatched from its associated latching assembly 314 by lifting a latching lever 318. The cross bar 304 extending between the rear supports 308 can then be lifted off of the latching assemblies 314, and the entire cargo supporting structure 302 pulled rearwardly so as to extend over the liftgate 12 b. The rear supports 308 are then latched to suitable latching structures formed in the liftgate 12 b at areas 322. The front supports 310 are then latched by closing the levers 316, which causes them to be locked on the slats 312 at the position shown in FIG. 21. If desired, notches 324 (one of which is shown in FIG. 20) could be formed in the slats 312 to define a specific position at which the front supports 312 must be placed in before same can be locked to the slats 312.

The apparatus 300 also provides a coupling member 326 associated with each front support 310 which provides two

pivot points

328 and 330. These two points of rotation are needed because the. point of rotation about which the liftgate 12 b rotates is laterally offset of the point of rotation of the cargo supporting structure 302. This allows the cargo supporting structure 302 to be easily articulated, together with the liftgate 12 b, as the liftgate 12 b is lifted, and without the need to first unlock the front supports 310 or the rear supports 308. Thus the apparatus 10 can be lifted simultaneously from the position shown in FIG. 21 into an intermediate position, wherein the cargo supporting structure 302 extends generally horizontally outwardly from the roof portion 12 a, such as in FIG. 2, before being pushed onto a position over the roof portion 12 a, without any binding action occurring at the coupling member 326.

Referring to FIG. 22, an articulating vehicle article carrier 400 is shown in accordance with another alternative preferred embodiment of the present invention. The article carrier 400 differs from the previous embodiments in that it is not able to be positioned on top of the roof of vehicle 402, but is quickly and easily removable from the vehicle 402 when it is not needed. Furthermore, the construction of the article carrier 400 is such that it is able to be placed in a compact arrangement, once removed, so that it can be stored conveniently within an area such as a garage, or even within a cargo area of the vehicle itself.

With further reference to FIG. 22, a pair of supports 404 are fixedly secured to a roof portion 406 of a vehicle 402. A cargo supporting structure 410 having a pair of upper coupling links 412 are pivotally attached to the supports at first ends 414 thereof. Second ends 416 are attached to a first or upper pair of pivot assemblies 418. The pivot assemblies 418 are also attached to first ends 420 of a pair of main support members 422. These support members 422 are illustrated as tubular, slightly curving members, but it will be appreciated that they could just as easily comprise different cross-sectional shapes. The main support members 422 are preferably comprised of aluminum to provide very light weight yet structurally strong members.

The main support members 422 are attached at second ends 424 thereof to a second pair of pivot assemblies 426. The second pair of pivot assemblies 426 are each in turn releasably engageable with a pair of anchor assemblies 428. Each of the anchor assemblies 428 are fixedly secured to a liftgate 408 of the vehicle 408. The cargo supporting structure 410 thus is positioned over the liftgate 408 when in use. Since the cargo supporting structure 410 is very lightweight, the presence of the structure 410 adds very little additional weight to the liftgate 408 when the liftgate is being lifted by a user. Thus, to the user, the effort required to lift the liftgate is almost the same whether or not the cargo supporting structure 410 is attached to the vehicle 408. FIG. 23 shows the article carrier 400 with the liftgate 408 in its raised position.

The cargo supporting structure 410 also preferably includes at least one, and more preferably a pair, of cross bars 430 supported on the main support members 422. Each of the cross bars 430 includes a mounting arm 432 at each of its opposite ends which are secured to a respective one of the main support members 422 at a predetermined position by a manually engageable fastening member 434. This coupling is shown in greater detail in FIG. 23A. The manually engageable fastening member 434 has an enlarged, manually graspable portion 434 a and a partially threaded portion 434 b. The partially threaded portion 434 b threadably engages with a tapped hole 434 c within each mounting arm 432. A rivnut 435 is also preferably included for allowing the cross bar 430 to be attached parallel to the support member 422 when the article carrier 400 is detached from the vehicle 408. This feature will be described in greater detail momentarily.

An additional feature of the cargo supporting structure 410 is that the cross bars 430 can be secured to the main support members 422 as illustrated in FIG. 24 when the structure 410 is removed from the vehicle 408 for storage. This is accomplished by the rivnut fastener 435 shown in FIG. 23A being included at a predetermined point along the length of each cross bar 430 to allow the separated cross bar 430 to be reattached via the fastening member 434 while positioned parallel to it. This also requires forming a hole at the proper point along the length of each support member 422 by which the fastening member 434 can be extended through. Each main support member 422 can then be handled separately in a compact configuration with one of the cross bars 430 attached to it. It will be appreciated that a variety of attachment or clamping mechanisms could readily be used to releasably secure the cross bars 430 generally parallel to the main support members 422. It will also be appreciated that the mounting arm 432 could be formed with one or more loop portions to facilitate the attachment of bungee cords or other fastening straps or cords. FIG. 24 also illustrates an alternative preferred form of mounting arm 432′ having such a loop portion 433′.

Referring to FIG. 25, the construction of one of the upper pivot assemblies 418 can be seen. It will be appreciated, however, that the construction of each of the lower pivot assemblies 426 is identical to that shown in FIG. 25. A first pivot element 439 includes a tubular free flange portion 439 a having an enlarged connecting ring 438. A second pivot element 441 also includes a tubular free flange portion 441 a and an enlarged connecting ring 440 having a slot 442 formed therein. The free flange portion 439 a is intended to be coupled to the second end 416 of the upper coupling link 412 with threaded fasteners or other conventional fastening means, while the free flange portion 441 a of the second pivot element 441 is intended to be secured to an end of one of the main support members 422.

The slot 442 is just slightly wider than the width of the connecting ring 438 such that it is. able to receive the connecting ring 438 therein. First and second identical coupling elements 444 each include an enlarged shoulder portion 446 and a hub portion 448. The hub portion 448 has an outer diameter which permits it to snugly slide within the connecting

rings

440 and 438 when the two

rings

440 and 438 are coupled together. The hub portion 448 includes a pair of slots 450 each having a somewhat flexible arm 452. The slots 450 open in opposite directions.

The two coupling elements 444 are secured to each other by first pressing each into the assembled connecting

rings

438 and 440 from opposite sides. The coupling elements 444 are then rotated slightly such that the arms 452 of each coupling element are aligned with the slot 450 of the other coupling element. Then the coupling elements 444 can be rotated in different directions, which causes each arm 452 to snap into engagement with the slot 450 of the opposite coupling element 444. At this point the first and

second pivot elements

439 and 441 will be securely held together while permitting pivotal movement of the upper coupling link 412 relative to its associated main support member 422. The opening formed in each pivot assembly also functions as a tie-down area where bungee cords or the like can be attached.

An alternative pivot assembly 460 is shown in FIG. 26. Pivot assembly 460 is similar to assembly 440 with the exception of a single piece locking hub 462. The locking hub includes a pair of shoulder portions 464 and 464 a spaced apart by a central hub portion 466. One or more slots 468 are formed to extend into the central hub portion 466 from the shoulder portion 464 a. When the locking hub 462 is inserted into the assembled combination of connecting

rings

438 and 440, with the shoulder portion 464 a being inserted first, that shoulder portion will compress slightly as it is forced through the connecting

rings

438 and 440. As it clears the second connecting ring 440 a it snaps out to lock the locking hub 462 within the connecting ring 440. Each of the first pivot assemblies 418 and second pivot assemblies 426, as well as the alternative pivot assembly 460 shown in FIG. 26, are all preferably made from high strength plastic but could also be formed from other suitably strong and lightweight materials.

With reference to FIG. 27, one of the supports 404 can be seen to include a recess 470 in which the first end 414 of one of the upper coupling links 412 is positioned. A conventional, manually engageable locking wheel 472 having a threaded shaft 474 extends through openings 476 in the first end 414 and into a threaded recess 478. When the locking wheel 472 is completely removed from the support 404 the upper coupling link 412 can be completely removed from the support.

Referring now to FIG. 28, one of the anchor assemblies 428 is shown. The anchor assembly 428 includes a flange portion 480 having a pair of openings 482. The openings 482 accommodate conventional fastening elements 483 that are used to secure the flange portion 480 to a suitable reinforcing member 484 within the liftgate 408.

The anchor assembly 428 also includes a tubular neck portion 486 integrally formed with or otherwise secured to the flange portion 480, and having a tapering end 486 a. The neck portion 486 has an opening 488 for receiving therethrough a locking element 490. The locking element 490 is inserted from the rear (i.e., initially through the flange portion 480) into the interior area of the tubular neck portion 486. The locking element 490 includes a biasing element 492 which is a Z-shaped piece of spring steel having a head portion 494 sized to protrude through the opening 488. The head portion 494 preferably has a beveled edge.

With reference to FIG. 29, to connect the lower pivot assembly 428 to its associated anchor assembly 428 the free flange portion 438 a is pushed over the tubular neck portion 486. The free flange portion 438 a includes an opening 496 aligned with the opening 488 in the neck portion when the free flange portion is urged over the neck portion 486. When this occurs, the head portion 494 of the locking element 490 is momentarily depressed as the free flange portion 438 a initially slides over the neck portion 486. As soon as the opening 496 reaches the opening 488, the head portion 494 snaps into the opening 488. To release the free flange portion 438 a, the user pushes down on the head portion 494 and pulls the free flange portion 438 a away from the neck portion 486. The beveled edge of the head portion 494 assists in causing the head portion 494 to be retracted.

Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims.

Claims

What is claimed is:

1. A vehicle article carrier for carrying articles adjacent a liftgate of a motor vehicle, the vehicle article carrier comprising:

a cargo supporting structure for supporting cargo:

a first support structure for supporting an upper end of said cargo supporting structure adjacent an upper edge of said liftgate;

an upper coupling structure pivotally secured to said upper end of said cargo supporting structure and pivotally to said first support structure;

a second support structure for supporting a lower end of said cargo supporting structure adjacent a lower edge of said liftgate; and

wherein said cargo supporting structure is readily removable from said support by a user; and

wherein said liftgate may be opened without interference from said cargo supporting structure when said cargo supporting structure is secured to said first support structure and positioned over said liftgate.

2. The vehicle article carrier of claim 1, further comprising:

a first pivot assembly for enabling said upper end of said cargo supporting structure to pivot relative to a roof portion of said vehicle.

3. The vehicle article carrier of claim 1, wherein said upper coupling structure comprises:

a first pivot assembly for enabling said upper end of said cargo supporting structure to pivot relative to a roof portion of said vehicle; and

a second pivot assembly for enabling said lower end of said cargo supporting structure to pivot relative to said liftgate as said liftgate is raised and lowered.

4. The vehicle article carrier of claim 1, wherein said second support structure comprises at least one anchor assembly for releasably securing said lower end of said cargo supporting structure to said liftgate.

5. The vehicle article carrier of claim 1, wherein said first support structure comprises a support fixedly secured to a roof of said vehicle; and

wherein said cargo supporting structure further comprises at least one upper coupling link pivotally coupled to said support.

6. The vehicle article carrier of claim 1, wherein:

said cargo supporting structure comprises a pair of main support members disposed generally parallel to one another; and

at least one cross bar secured between said main support members.

7. A vehicle article carrier for supporting articles adjacent a liftgate of a vehicle, said vehicle article carrier comprising:

a cargo supporting structure comprising an upper end and a lower end;

an upper coupling structure pivotally secured to said upper end of said cargo supporting structure via an upper pivot assembly;

a support secured to a roof of said vehicle and pivotally secured to said upper coupling structure;

a lower pivot assembly secured to said lower end of said cargo supporting structure for pivotally securing said lower end of said cargo supporting structure to said liftgate adjacent a lower end of said liftgate;

wherein said upper coupling structure is releasably coupled to said support; and

wherein said lower pivot assembly is releasably coupled to said lower end of said liftgate such that said cargo supporting structure and said upper coupling structure is completely removable from said vehicle without the use of any external tools.

8. The vehicle article carrier of claim 7, further comprising a user actuatable fastening member associated with said support for releasably and pivotally securing said upper coupling structure to said support.

9. The vehicle article carrier of claim 7, further comprising an anchor assembly fixedly secured to said liftgate for releasably engaging with said lower pivot assembly.

10. The vehicle article carrier of claim 7, wherein said cargo supporting structure comprises a pair of main support members disposed generally parallel to one another and in spaced apart relation to one another.

11. The vehicle article carrier of claim 10, further comprising at least one cross bar secured between said main support members.

12. The vehicle article carrier of claim 11, wherein said cross bar includes a fastening structure for enabling said cross bar to be secured to one of said main support members so as to extend generally parallel to said one main support member.

13. The vehicle article carrier of claim 7, further comprising a user actuatable fastening member operably associated with said support for securing said upper coupling structure to said support and for permitting detachment of said upper coupling structure from said support.

14. A vehicle article carrier for supporting articles adjacent a liftgate of a motor vehicle, the vehicle article carrier comprising:

a supporting structure fixedly secured to a roof of said vehicle:

a cargo supporting structure;

an upper coupling structure having first and second pivot assemblies for pivotally securing an upper end of said cargo supporting structure to said support structure;

said cargo supporting structure including a lower end secured to said liftgate adjacent a lower portion of said liftgate, and a lower pivot assembly at said lower end of said cargo supporting structure to permit said cargo supporting structure to be lifted with said liftgate while said lower end is secured to said liftgate; and

wherein said cargo supporting structure can be detached from said vehicle without external tools.

15. The vehicle article carrier of claim 14, further comprising an anchor assembly adapted to be secured to said lower pivot assembly for detachably securing said lower end of said cargo supporting structure to said liftgate.

16. The vehicle article carrier of claim 14, wherein said cargo supporting structure comprises a pair of said main support members disposed generally parallel to one another and a cross bar extending therebetween.

17. The vehicle article carrier of claim 14, wherein said support structure includes a user actuatable fastening member for detachably securing said upper end of said cargo supporting structure thereto.